Simplifying Opto- Mechanical Product Development: How a new product reduces cost, stress, and time to market

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1 Simplifying Opto- Mechanical Product Development: How a new product reduces cost, stress, and time to market Innovation in optical design is exploding. From cell phone cameras to space telescopes, driverless cars to the LIGO laser interferometer, optics have transformed our lives. Optical system design and the optical engineer s toolbox have evolved over the last two decades. What used to take optical engineers months to design can now be designed in a matter of hours or days. Using optical simulation software such as OpticStudio from Zemax, optical engineers can design optical systems that could not have been imagined 20 years ago. Limited toolbox for opto- mechanical engineers Although the toolbox for optical engineers has expanded to drive innovation and meet today s challenges, opto- mechanical engineers have been left far behind. Until now, no good toolset has existed to solve opto- mechanical challenges. Further, optical engineers and opto- mechanical engineers address different challenges. Optical engineers use OpticStudio to lay out a lens system. Essentially, they create lenses and components in free space. They design the shapes and determine the positions of the lenses, mirrors, prisms, gratings, and other optical components to achieve a given performance goal and to meet the design specifications. In contrast, opto- mechanical engineers design and build the packaging for the lens design. They are concerned about the materials, finishes, thermal design, stress, vibration, tolerancing, manufacturability, cost of manufacturing, and other considerations that may affect the optical performance or the success of the product. They must also design for brand consistency and user experience concerns, such as the industrial design, weight, look and feel, and durability. Figures 1 and 2 compare a 25mm lens design in free space versus fully packaged. Figure 1. A 25mm lens design in free space Figure 2. The same 25mm lens design packaged in LensMechanix Inefficient workflow In addition to addressing different challenges, optical engineers and opto- mechanical engineers work in different design environments and speak different languages. The process workflow between them is inefficient and cumbersome. In most cases, opto- mechanical engineers receive an exported STEP or IGES file in a Computer- Aided Design (CAD) program from an optical simulation package. These data blobs

2 do not include optics design files or data about the components, such as materials, coatings, surface radii, edges, tolerances, wavelengths, or clear aperture location. Figure 1 shows an IGES file of a 25mm lens with a ray bundle imported into SOLIDWORKS. Opto- mechanical engineers must manually rebuild the optical system within the CAD package, which is time consuming and can introduce errors. For a complex optical system such as a telescope with many lenses, rebuilding the optical components in a CAD program can take days or weeks. After importing and rebuilding the optical components, opto- mechanical engineers can start building the mechanical geometry and analyzing their design. However, there are no tools to help them assess the impact of their design on the optical system. They must either export the design back to the optical engineer to validate the design or build physical prototypes to assess the product s performance. The cycle of prototype and redesign can be repeated many times before the opto- mechanical design is finalized. These repeated design iterations increase costs, create stress within the design team, and delay time to market. They also negatively impact the optical engineer, who typically works with several opto- mechanical engineers at one time. Validating each opto- mechanical engineer s designs (often multiple times) creates a bottleneck in the workflow and a high opportunity cost for the organization by reducing the amount of time the optical engineer could spend developing new optical systems for the market. Improving opto- mechanical product development with LensMechanix To equip opto- mechanical engineers with the tools they need to package, analyze, and validate opto- mechanical designs, Zemax recently created LensMechanix software for simulation and analysis. This powerful SOLIDWORKS plug- in simplifies the transition between optics design and opto- mechanical packaging. For the first time, opto- mechanical engineers can analyze and validate their designs in SOLIDWORKS, including full multi- threaded ray tracing using the industry- standard Zemax ray tracing engine. LensMechanix loads optical systems from Zemax s OpticStudio directly into a SOLIDWORKS assembly. LensMechanix handles both sequential and nonsequential designs. All of the data associated with the optical components is preserved, such as materials, coatings, surface radii, edges, wavelengths, and clear aperture location. It also loads sources and detectors. LensMechanix automatically creates the optical component parts with actual lens dimensions, eliminating the need for STEP and IGES files. Within minutes, opto- mechanical engineers can start building mechanical geometry from the dimensionally accurate optical components, and then run ray traces and perform surface power analysis to compare the optical performance in SOLIDWORKS with the original OpticStudio output. LensMechanix uses Zemax s core physics engine for ray tracing, which makes it easy for opto- mechanical engineers to discover and correct stray light contamination, beam clipping, image focus issues, or other potential issues caused by the mechanical geometry before they build a prototype or send the design to the optical engineering to review. As seen in Figure 3, a simple chart indicates pass/fail for image quality and stray light metrics. Detailed results data is also stored so that opto- mechanical engineers can troubleshoot the design or gather additional insights.

3 Figure 3. Pass/fail results for opto- mechanical design LensMechanix includes the following packaging, analysis, and validation tools. Packaging tools Analysis tools Validation tools 1. Ability to insert OpticStudio files into SOLIDWORKS 2. Ability to save OpticStudio files from SOLIDWORKS 3. Ambient Conditions Control 4. Wavelengths Control 5. Surface Property Control 6. Reference Geometry 1. Full Ray Trace 2. Surface Power 3. Image Viewer 4. Ray Scattering and Ray Splitting Control 5. Analysis Precision Control 6. Baseline Ray Trace 7. Quick Trace 8. Scatter profiles Figure 4. Packaging, analysis, and validation tools in LensMechanix 1. Optical Performance Summary table 2. OpticStudio Baseline results 3. LensMechanix Baseline results 4. Beam Size validation 5. Footprint validation Challenges of stray light and beam clipping Mechanical product development can degrade optical performance in many ways. Two common problems are stray light and beam clipping. In this article, we use a 25mm single Gauss lens system to demonstrate stray light and a possible solution. Stray light can be introduced into an optical system in many ways. Even subtle changes to the mechanical geometry can have a major impact on optical performance. As shown in Figure 5, the 45⁰ chamfer on the front retaining ring directs light onto the interior mechanical and optical surfaces. The reflected light propagates through the system, degrading the image quality.

4 45⁰ chamfer Figure 5. The 45⁰ angle of the chamfer introduces stray light Changing the chamfer angle on the front retaining ring from a 45⁰ chamfer to a small step or series of steps greatly reduces the amount of stray light entering the optical system. Figure 6 shows the front retaining ring corrected with a single step surface. 45⁰ chamfer is replaced with a step Figure 6. The stray light is corrected by changing the chamfer angle to a step Applying an absorptive coating such as Acktar s Fractal Black can help mitigate stray light. Absorptive coatings are optimized to perform for specific wavelength ranges and must be matched to the optical system requirements. Figure 7 shows how Acktar s Fractal Black coating minimizes reflectance through a portion of the spectrum in opto- mechanical designs.

5 Figure 7. Reflectance vs. wavelength for Acktar s Fractal Black coating Source: Acktar Ltd. The best method of reducing stray light highly depends on the product that you are developing. The opto- mechanical engineer needs to consider the manufacturing and assembly processes in addition to materials, finishes, and cost. Another common problem is beam clipping, which occurs when mechanical geometry interferes with light entering an aperture. The lens boundary that is intended for light to pass through is called the clear aperture. Figure 8 shows an example of the clear aperture location of lens surface 1. The clear aperture Figure 8. The location of the clear aperture on lens surface 1 Any mechanical geometry that extends into the clear aperture will cause beam clipping. As seen in the photo in Figure 9, the mechanical geometry is preventing light from filling the entire aperture; as a result, the beam is clipped.

6 Beam clipping Figure 9. Example of beam clipping To evaluate beam clipping, today an optical engineer provides a ray bundle to the opto- mechanical engineer. A ray bundle file is the static ray trace output from the optical simulation package. Figure 10 shows an optical system imported with a static ray bundle. Figure 10. A STEP file imported with a static ray bundle As the mechanical packaging takes shape, the opto- mechanical engineer manually overlays the ray bundle onto the design to check that the rays do not hit the mechanical geometry. The static ray bundle, however, may not account for all of the mechanical geometry. When the mechanical packaging is large compared to the optical system, the opto- mechanical engineer must manually extend rays to account for all of the mechanical geometry. If the opto- mechanical engineer uses a fold mirror to change the direction of the light, it renders the new static ray bundle useless, and he or she must start over with a new design from the optical engineer. LensMechanix can trace rays through an opto- mechanical system that has been modified with a fold mirror. Conclusion

7 LensMechanix streamlines the workflow between optical engineers and opto- mechanical engineers, who can collaborate efficiently while working in their preferred environments and formats. With the tools to validate their own designs, opto- mechanical engineers can eliminate repeated prototypes and extra development iterations, dramatically saving time for themselves and for optical engineers, improving collaboration, and speeding delivery to manufacturing. An opto- mechanical engineer recently commented about LensMechanix, Thank you for developing this. I've been doing this kind of transfer the "hard way" with STEP files and iteration with the optical designers for almost 20 years.

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